Brake Force Generator Planet Carrier for Stable Gear Mounting
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Solution Overview
Problem
Existing brake force generators in automotive brake systems face challenges in achieving stable mounting of the planet gear on the planet carrier, which affects the overall stability and efficiency of the brake system.
Innovation Solution
The proposed solution involves a brake force generator design where the planet carrier has a hollow shaft segment with radial through-openings for the planet gears, and the planet gear shaft is mounted on both sides of the planet gear, providing enhanced stability and allowing for the use of a cost-effective plastic planet carrier.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the planet gear is mounted on one side at an end face of the planet carrier (conventional solution), then the device complexity is reduced, but the stability of the planet gear mounting deteriorates
Solution Approach 1:
The planet gear shaft is extended from a single-sided mounting (one-dimensional constraint) to a dual-sided mounting through the hollow shaft segment (two-dimensional constraint). This dimensional change in the mounting approach provides enhanced stability without significantly increasing overall device complexity, as the hollow shaft segment naturally accommodates the dual-sided configuration.
Solution Approach 2:
The planet gear shaft is nested within the hollow shaft segment of the planet carrier, with the planet gear positioned between the two ends of the shaft. This nesting arrangement allows the planet gear to be securely mounted on both sides while utilizing the existing hollow structure of the planet carrier, thereby improving stability without adding substantial external complexity.
2Reliability
If a metal planet carrier is used to ensure stable mounting, then the stability of the planet gear mounting is improved, but the manufacturing cost increases
Solution Approach 1:
The solution employs a composite material approach by combining a plastic planet carrier with a metal hollow shaft segment and metal planet gear shaft. This hybrid construction allows the planet carrier to be manufactured cost-effectively from plastic while incorporating metal components only where structural strength and stability are critically needed, thereby achieving reliable planet gear mounting without the expense of a fully metal planet carrier.
Solution Approach 2:
Instead of making the entire planet carrier from expensive metal, the invention applies metal material properties locally to the hollow shaft segment and planet gear shaft where mounting stability is required. The bulk of the planet carrier remains plastic for cost-effective manufacturing, while the critical mounting regions incorporate metal components to provide the necessary strength and stability.
3Reliability
If the planet gear shaft is mounted on both sides of the planet gear, then the stability and wear resistance is improved, but the device complexity increases
Solution Approach 1:
The planet gear shaft is nested within the hollow shaft segment, with the planet gear positioned between the two ends. This nesting configuration allows dual-sided mounting that improves stability and wear resistance while utilizing the existing hollow structure, thereby minimizing the increase in device complexity.
Solution Approach 2:
The mounting approach transitions from single-sided to dual-sided through the hollow shaft segment, adding a dimensional aspect to the constraint system. This dimensional enhancement provides improved stability and wear resistance while the hollow shaft segment naturally accommodates the configuration without requiring additional external structures.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design ensures a particularly stable mounting of the planet gear, reducing wear and allowing for efficient conversion of rotational motion into translational motion, thereby enhancing the overall performance and reliability of the brake system.
Implementation Method 1
an electric motor that has a rotor and at least one motor winding, the rotor being situated in rotationally fixed fashion on the driveshaft and being rotatable through an application of current to the motor winding
Implementation Method 2
a transmission device that acts between the driveshaft and the actuating element in such a way that the actuating element is displaced when there is a rotation of the driveshaft, the transmission device having a planetary gear mechanism
Data Source
AI summary
A brake force generator for a brake system. The brake force generator includes a driveshaft rotatably mounted in a housing, an electric motor, a displaceably mounted actuating element, and a transmission device that acts between the driveshaft and the actuating element in such a way that when there is a rotation of the driveshaft the actuating element is displaced. The transmission device has a planetary gear mechanism that has a sun gear connected in rotationally fixed fashion to the driveshaft, a rotatably mounted planet carrier, and at least one planet gear that is rotatably mounted on the planet carrier by a planet gear shaft. The planet carrier has a hollow shaft segment, and a jacket wall of the hollow shaft segment having a radial through-opening in which the planet gear lies. The planet gear shaft is mounted in the hollow shaft segment at both sides of the planet gear.